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Relay acting funny. (electrical issue)

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BananaLover
Borekit Bruiser



Joined: 08 May 2017
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PostPosted: 18:18 - 31 Jul 2018    Post subject: Relay acting funny. (electrical issue) Reply with quote

Some time ago I tore off a wire going into the block connector that goes into my relay, it was the power wire (to start the bike), I soldiered it back and it worked fine for a while. Like a month later my bike wouldn't start again (press the button and nothing happens) but if I kept the button down for long enough eventually it would start kicking. Couple days back it just wouldn't start at all, figured it's the connection I undid the soldering part and tested voltage and here's the weird part - once I turn the key I hear a click from the replay (like expected) and the wire gets 12V but like a second or two later I hear another click and the voltage drops to nothing. What could this mean?
I can't start it even during the turn key phase where it gets power for those two seconds. (I press the button but nothing happens)

I checked the fuses and fully charged the battery.
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Itchy
Super Spammer



Joined: 07 Apr 2005
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PostPosted: 18:26 - 31 Jul 2018    Post subject: Reply with quote

You're not having much luck with this bike.

I think you mean the starter relay right?

My first guess would be that your starter relay has rot from inside out. Take the relay out and look for green (statue of liberty green) corrosion.

Then shake it gently and listen to it. If it sounds like it's filled with salt then it's internally corroded.

I'd type more but a video says more:

https://www.youtube.com/watch?v=gV7j3e1as6c
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BananaLover
Borekit Bruiser



Joined: 08 May 2017
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PostPosted: 18:48 - 31 Jul 2018    Post subject: Reply with quote

Yeah, unfortunately I've had a lot of bad luck with my bike but it's old I'm just happy to own one.

My relay looks similar to this one https://images.wemoto.com/full/FLASHER_RELAY/10038797.jpg
but with more pins. I can't have it plugged in while testing resistance like the video suggests. (if I understood it right)

It is the starter relay, this is the best picture of the circuit that I could find in my manual https://i.imgur.com/1VWxQlk.jpg

The ignition wire is the one that stops getting voltage on the second click, but fuel pump wire for example is getting full voltage. I find it unlikely that exactly the wire I was having trouble with from the start is also now the one not getting power because relay itself is at fault now for an unrelated reason. I will try the test you suggested. The liberty statue coloured (copper corrosion ?) was the reason wire tore off initially though.
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Hawkeye1250FA
World Chat Champion



Joined: 14 Oct 2016
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PostPosted: 20:09 - 31 Jul 2018    Post subject: Reply with quote

Relay dead.

Buy new relay. Very cheap. Easy fix. Ride into sunset.

Smile at possibly the cheapest and easiest fix your bike will ever see.
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1993 RF400R - 2002 Bandit 1200 - 2012 1250 FA
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Stalk
Brolly Dolly



Joined: 26 Dec 2005
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PostPosted: 12:35 - 01 Aug 2018    Post subject: Reply with quote

Silly question but, your battery isn't flat is it?
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BananaLover
Borekit Bruiser



Joined: 08 May 2017
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PostPosted: 21:20 - 03 Aug 2018    Post subject: Reply with quote

Stalk wrote:
Silly question but, your battery isn't flat is it?

I mentioned that I fully charged the battery in OP.

I've replaced the relay and nothing has changed.
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Hawkeye1250FA
World Chat Champion



Joined: 14 Oct 2016
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PostPosted: 21:24 - 03 Aug 2018    Post subject: Reply with quote

How very odd.

I'd check the microswitches on things that stop it starting. (clutch? Sidestand?)
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1993 RF400R - 2002 Bandit 1200 - 2012 1250 FA
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stinkwheel
Bovine Proctologist



Joined: 12 Jul 2004
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PostPosted: 00:04 - 04 Aug 2018    Post subject: Reply with quote

Bike is what?

If it's a late 90's kawasaki, I'd have a good look at the main fuse holder for signs of corrosion. If it is, cut it back to clean metal and splice in a new piece of wire.
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“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
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BananaLover
Borekit Bruiser



Joined: 08 May 2017
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PostPosted: 14:10 - 07 Aug 2018    Post subject: Reply with quote

One of the other wires was pretty corroded, I replaced all the pins and it works.
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stinkwheel
Bovine Proctologist



Joined: 12 Jul 2004
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PostPosted: 15:19 - 07 Aug 2018    Post subject: Reply with quote

Bike is what?

I swear. We should get Korn to make make, mode and year a required field before you can post in the workshop section.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
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